Monofilament bristle assemblies and methods of making brushes using same

Abstract

Several brush assemblies are disclosed. All employ bristle strings that include a base string connected to a plurality of monofilaments. The preferred monofilaments are nylons and other polymeric thermoplastic materials. The monofilaments may be linear segments or loop segments disposed in two rows. The bristle strings may be connected to brush bodies to form virtually any of the various types of brushes. Bristle strings employing loops may be braided together to form entangled, monofilament articles for brush or other applications.

What is claimed is:  
     
       1. A bristle sub-assembly comprising: 
       a first support structure comprising an elongated base string having a defined, solid physical structure with a regular, geometric shape and an outer surface; and  
       a second bristle structure comprising a plurality of monofilaments, each having a defined, solid physical structure with a regular, geometric shape and an outer surface and;  
       a flow zone disposed at locations where the outer surfaces of the monofilaments of the second bristle structure contact the outer surface of the base string,  
       the flow zone defining a joint between outer surfaces of the monofilaments and the outer surface of the base string.  
     
     
       2. A bristle subassembly according to claim  1 , wherein the monofilaments are made of a polymeric material. 
     
     
       3. A bristle sub-assembly according to claim  2 , wherein the polymeric material is a thermoplastic polymeric material. 
     
     
       4. A bristle sub-assembly according to claim  1 , wherein the base string comprises a monofilament strand made of a polymeric material. 
     
     
       5. A bristle sub-assembly according to claim  4 , wherein the polymeric material is a thermoplastic polymeric material. 
     
     
       6. A bristle sub-assembly according to claim  1 , wherein the monofilaments are made of a material selected from the group consisting of aliphatic polyamides, aromatic polyamides, polyesters, polyolefins, styrenes, polyvinylchloride (PVC), fluoropolymers, polyurethane, polyvinylidene chloride, and polystyrene and styrene copolymers. 
     
     
       7. A bristle sub-assembly according to claim  1 , wherein the monofilaments are made of a material selected from the group consisting of nylon and nylon co-polymers. 
     
     
       8. A bristle sub-assembly according to claim  7 , wherein the material is selected from the group consisting of 4 nylon, 6 nylon, 11 nylon, 12 nylon, 6,6 nylon, 6,10 nylon, 6,12 nylon, 6,14 nylon, 10,10 nylon and 12,12 nylon. 
     
     
       9. A bristle sub-assembly according to claim  1 , wherein at least one of the base string and the monofilaments are made of polybutylene terephthalate (PBT). 
     
     
       10. A bristle sub-assembly according to claim  1 , wherein the monofilaments have non-circular cross-sectional shapes. 
     
     
       11. A bristle sub-assembly according to claim  1 , wherein at least one of the base string and the monofilaments have at least one continuous cavity. 
     
     
       12. A bristle sub-assembly according to claim  1 , wherein at least one of the base string and the monofilaments have non-continuous voids. 
     
     
       13. A bristle sub-assembly according to claim  1 , wherein the base string is a monofilament made of thermoplastic material having a diameter of 2-200 mils. 
     
     
       14. A bristle sub-assembly according to claim  1 , wherein the monofilaments have substantially circular cross-sectional shapes. 
     
     
       15. A bristle sub-assembly according to claim  1 , wherein the base string has a non-circular cross-sectional shape. 
     
     
       16. A bristle sub-assembly according to claim  1 , wherein the base string has a substantially circular cross-sectional shape. 
     
     
       17. A bristle sub-assembly according to claim  1 , wherein the base string is a bundle of monofilaments, at least one of which is made of a thermoplastic, polymeric material. 
     
     
       18. A bristle sub-assembly according to claim  17 , wherein the at least one monofilament included in the bundle is made of material selected from the group consisting of aliphatic polyamides, aromatic polyamides, polyesters, polyolefins, styrenes, polyvinylchloride (PVC), polyurethane, fluoropolymers, polyvinylidene chloride, and polystyrene and styrene copolymers. 
     
     
       19. A bristle sub-assembly according to claim  1 , wherein the monofilaments include an additive selected from the group consisting of colorants, color particles, therapeutic agents, anti-microbial agents, and combinations thereof. 
     
     
       20. A bristle sub-assembly according to claim  1 , wherein the monofilaments include 0-50% by weight abrasive particles. 
     
     
       21. A bristle sub-assembly according to claim  20 , wherein the abrasive particles are selected for their abrasive properties from the group consisting of oxides, carbides, silicates, nitrides, borides, boro-nitrides, and metals. 
     
     
       22. A bristle sub-assembly according to claim  1 , wherein at least one of the base string and the monofilaments are co-extrusions of at least one polymer. 
     
     
       23. A bristle sub-assembly according to claim  1 , wherein at least one of the base string and the monofilaments are surface treated. 
     
     
       24. A bristle sub-assembly according to claim  1 , wherein the monofilaments are nonlinear. 
     
     
       25. A bristle subassembly according to claim  1 , wherein the monofilaments are heat fused to the base string. 
     
     
       26. A bristle sub-assembly according to claim  1 , wherein the monofilaments are connected transversely to the base string to form first and second rows of monofilament segments. 
     
     
       27. A bristle sub-assembly according to claim  26 , wherein the first row of monofilament segments are substantially straight and disposed in a first plane with minimum angular variance, and the second row of the monofilament segments are substantially straight and disposed in a second plane with minimum angular variance. 
     
     
       28. A bristle sub-assembly according to claim  1 , wherein the monofilaments have a diameter of 2 to 200 mils. 
     
     
       29. A bristle sub-assembly according to claim  1 , wherein the monofilaments have varying diameters of 2 to 200 mils. 
     
     
       30. A bristle sub-assembly according to claim  1 , wherein the monofilaments have varying properties selected from the group consisting of shapes, lengths, materials, and colors, and combinations thereof. 
     
     
       31. A bristle sub-assembly according to claim  1 , wherein each of the monofilaments is a loop connected to the base string. 
     
     
       32. A bristle subassembly according to claim  31 , wherein the monofilament loops are connected to the base string substantially in first and second rows. 
     
     
       33. A bristle sub-assembly according to claim  1 , wherein the monofilaments include a combination of straight polymeric monofilament segments and looped polymeric monofilament segments. 
     
     
       34. A bristle sub-assembly according to claim  1 , wherein the monofilaments have a diameter of 2 to 20 mils. 
     
     
       35. A bristle sub-assembly according to claim  1 , wherein the monofilaments have varying diameters of 2 to 20 mils. 
     
     
       36. A brush assembly comprising: 
       a brush body; and  
       at least one bristle sub-assembly connected to the brush body, and including a first support structure comprising a an elongated base string having a defined, solid physical structure with a regular, geometric shape and an outer surface and a second bristle structure comprising a plurality of monofilaments, each having a defined, solid physical structure with a regular, geometric shape and an outer surface; and  
       a flow zone disposed at locations where the outer surfaces of the monofilaments of the second bristle structure contact the outer surface of the base string,  
       the flow zone defining a joint between outer surfaces of the monofilaments and the outer surface of the base string.  
     
     
       37. A brush assembly according to claim  36 , wherein the monofilaments are made of a polymeric material. 
     
     
       38. A brush assembly according to claim  37 , wherein the polymeric material is a thermoplastic polymeric material. 
     
     
       39. A brush assembly according to claim  36 , wherein the base string is a single monofilament made of a polymeric material. 
     
     
       40. A brush assembly according to claim  39 , wherein the polymeric material is a thermoplastic polymeric material. 
     
     
       41. A brush assembly according to claim  36 , wherein the base string is a bundle of monofilaments, at least one of which is made of a thermoplastic, polymeric material. 
     
     
       42. A brush assembly according to claim  41 , wherein the at least one monofilament included in the bundle is made of material selected from the group consisting of aliphatic polyamides, aromatic polyamides, polyesters, polyolefins, styrenes, polyvinylchloride (PVC), fluoropolymers, polyurethane, polyvinylidene chloride, and polystyrene and styrene copolymers. 
     
     
       43. A brush assembly according to claim  36 , wherein the monofilaments are made of a material selected from the group consisting of aliphatic polyamides, aromatic polyamides, polyester, polyolefins, styrenes, polyvinylchloride (PVC), fluoropolymers, polyurethane, polyvinylidene chloride, and polystyrene and styrene copolymers. 
     
     
       44. A brush assembly according to claim  36 , wherein the monofilaments are made of a material selected from the group consisting of nylon and nylon co-polymers. 
     
     
       45. A brush assembly according to claim  44 , wherein the nylon material is selected from the group consisting of 4 nylon, 6 nylon, 11 nylon, 12 nylon, 6,6 nylon, 6,10 nylon, 6,12 nylon. 6,14 nylon, 10,10 nylon, and 12,12 nylon. 
     
     
       46. A brush assembly according to claim  36 , wherein at least one of the base string and the polymeric monofilaments are made of polybutylene teraphthalate (PBT). 
     
     
       47. A brush assembly according to claim  36 , wherein the brush body is made of a material selected from the group consisting of polymer, metal, and wood. 
     
     
       48. A brush assembly according to claim  36 , wherein the monofilaments are heat fused to the base string. 
     
     
       49. A brush assembly according to claim  36 , wherein the monofilaments includes a plurality of polymeric monofilament segments connected transversely to the base string to form first and second legs. 
     
     
       50. A brush assembly according to claim  49 , wherein the first and second legs of each bristle string are bent substantially parallel to each other and the base string is embedded in the brush body to thereby maintain the first and second legs in the substantially parallel position. 
     
     
       51. A brush assembly according to claim  36 , wherein the brush body includes a plurality of grooves and the brush assembly further includes means for detachably coupling at least one of the bristle sub-assemblies in a corresponding groove. 
     
     
       52. A brush assembly according to claim  36 , wherein the body comprises at least one wire intertwined with the bristle sub-assembly. 
     
     
       53. A brush assembly according to claim  36 , wherein the body includes a plurality of grooves and each bristle sub-assembly includes a cartridge having the base string embedded therein and the monofilaments extending upwardly from the cartridge. 
     
     
       54. A brush assembly according to claim  53 , wherein the cartridge of each bristle sub-assembly is detachably received in the grooves of the body. 
     
     
       55. A brush assembly according to claim  36 , wherein the body includes a handle portion and a head portion, wherein the monofilaments of each bristle sub-assembly include first and second monofilament segments disposed in first and second rows, wherein the first and second rows are bent toward each other to form a bristle string, and wherein at least one bristle string is connected to the head portion of the body. 
     
     
       56. A brush assembly according to claim  36 , wherein each of the monofilaments is a loop connected to the base string. 
     
     
       57. A brush assembly according to claim  56 , wherein the monofilament loops are connected to the base string substantially in first and second rows. 
     
     
       58. A brush assembly according to claim  36 , wherein at least one of the base string and the monofilaments has a diameter of 2 to 200 mils. 
     
     
       59. A brush assembly according to claim  36 , wherein the polymeric monofilaments have a diameter of 2 to 20 mils. 
     
     
       60. A brush assembly according to claim  36 , wherein at least one of the base string and the monofilaments have diameters that vary between 2 and 20 mils. 
     
     
       61. A brush assembly according to claim  36 , wherein the monofilaments include a combination of substantially linear monofilament segments and substantially looped monofilament segments. 
     
     
       62. A brush assembly according to claim  36 , wherein the at least one bristle sub-assembly includes at least two bristle sub-assemblies disposed in a common row. 
     
     
       63. A brush assembly according to claim  62 , wherein one bristle sub-assembly has straight monofilaments and the other has looped monofilaments. 
     
     
       64. A method of making a brush comprising the steps of: 
       forming at least one bristle sub-assembly by joining a base string to a plurality of monofilaments at abutting outer surfaces of the base string and the monofilaments;  
       providing a brush body in a predetermined size and shape; and  
       connecting the at least one bristle sub-assembly to the brush body,  
       wherein the base string has a defined, solid physical structure with a regular, geometric shape and an outer surface, and each of the plurality of monofilaments has a defined, solid physical structure with a regular, geometric shape and an outer surface, and  
       where in the forming step further comprises forming a flow zone disposed at locations where the outer surfaces of the monofilaments contact the outer surface of the base string,  
       the flow zone defining a joint between outer surfaces of the monofilaments and the outer surface of the base string.  
     
     
       65. A method according to claim  64 , wherein the step of forming at least one bristle sub-assembly includes providing a base string and connecting a plurality of polymeric monofilaments to the base string thereby forming a structure having at least one row of monofilament bristles connected to the base string. 
     
     
       66. A method according to claim  65 , further comprising forming a plurality of grooves in the brush body and the forming step includes providing an elongated base string and cutting the base string into a plurality of segments, thus forming a plurality of bristle sub-assemblies, and the connecting step includes fitting and anchoring at least two bristle sub-assemblies in at least one of the grooves. 
     
     
       67. A method according to claim  64 , wherein the step of forming at least one bristle sub-assembly includes forming a plurality of loops from a monofilament strand, and connected the loops to the base string to form substantially two rows of monofilament loop segments. 
     
     
       68. A method according to claim  64 , wherein the step of providing a brush body includes providing at least one wire, and the step of connecting the at least one bristle sub-assembly to the brush body includes twisting the at least one bristle string and wire together. 
     
     
       69. A method according to claim  64 , wherein the step of forming at least one bristle sub-assembly includes providing a base string and connecting a plurality of polymeric monofilaments to the base string, thereby forming a V-shaped structure having first and second rows of monofilament bristles, and wherein the bending step includes bending the first and second rows of monofilament bristles together to form a single, substantially vertically oriented row that extends upwardly from the base string, and molding the base string and proximal end portions of the first and second rows of monofilament bristles into the body. 
     
     
       70. A method according to claim  64 , further comprising forming a plurality of grooves in the brush body, the step of forming at least one bristle sub-assembly includes forming a plurality of bristle sub-assemblies of desired lengths, and the connecting step includes fitting respective ones of the bristle sub-assemblies into a corresponding groove. 
     
     
       71. A method according to claim  70 , further comprising anchoring each bristle sub-assembly in each corresponding groove by use of at least one of a solvent, thermal and mechanical means. 
     
     
       72. A method according to claim  64 , wherein the step of providing a brush body includes forming a plurality of substantially parallel grooves, the step of forming at least one bristle sub-assembly includes forming at least one bristle cartridge having a support strip and a plurality of monofilaments extending upwardly from the support strip, and the step of connecting at least one bristle string to the brush body includes fitting the at least one bristle cartridge into a respective groove. 
     
     
       73. An article comprising: 
       a first monofilament sub-assembly which includes a base string and a plurality of monofilament loops connected to the base string; and  
       a second monofilament sub-assembly which includes a base string and a plurality of monofilament loops connected to the base string,  
       the monofilament loops of the first and second monofilament sub-assemblies being entangled with each other.  
     
     
       74. An article according to claim  73 , wherein the base strings of the first and second monofilament sub-assemblies are twisted together to thereby entangle the monofilament loops of the first and second monofilament sub-assemblies. 
     
     
       75. An article according to claim  73 , wherein the monofilament loops of the first and second monofilament sub-assemblies are made of material selected from the group consisting of aliphatic polyamides, aromatic polyamides, polyesters, polyolefins, styrenes, polyvinylchloride (PVC), polyurethane, fluoropolymers, polyvinylidene chloride, and polystyrene and styrene copolymers. 
     
     
       76. An article according to claim  73 , further comprising a third monofilament sub-assembly which includes a base string and a plurality of monofilament loops connected to the base string, the base strings of the first, second and third monofilament sub-assemblies being braided together to thereby entangle the monofilament loops of the first, second and third monofilament sub-assemblies. 
     
     
       77. A bristle sub-assembly comprising: 
       a first base string having a groove;  
       a plurality of monofilaments disposed in a substantially linear, parallel array substantially transverse the groove;  
       a second base string shaped to fit within and interlock with the groove of the first base string, to thereby bind the monofilaments within the groove and form first and second rows of monofilament segments which extend outwardly from the interlocking first and second base strings.  
     
     
       78. A bristle sub-assembly according to claim  77 , wherein the at least one base string includes at least two base strings woven between the monofilaments. 
     
     
       79. A bristle sub-assembly according to claim  77 , wherein the plurality of monofilaments are made of material selected from the group consisting of aliphatic polyamides, aromatic polyamides, polyesters, polyolefins, styrenes, polyvinylchloride (PVC), polyurethane, fluoropolymers, polyvinylidene chloride, and polystyrene and styrene copolymers. 
     
     
       80. A bristle sub-assembly according to claim  77 , wherein the at least one base string includes two base strings disposed respectively below and above the monofilaments and in alignment with each other, the two base strings interlocking with each other to capture the monofilaments therebetween. 
     
     
       81. A bristle sub-assembly according to claim  77 , wherein at least one of the base string and the monofilaments are made of a material selected from the group consisting of polymer, glass, metal, and ceramic. 
     
     
       82. A bristle sub-assembly according to claim  77 , wherein the base string is made of material selected from the group consisting of aliphatic polyamides, aromatic polyamides, polyesters, polyolefins, polyethylene, polypropylene, styrenes, polyvinylchloride (PVC), fluoropolymers, polyurethane, fluoropolymers, polyvinylidene chloride, and polystyrene and styrene copolymers. 
     
     
       83. A bristle sub-assembly according to claim  77 , wherein the plurality of monofilaments are made of a nylon material. 
     
     
       84. A bristle sub-assembly according to claim  83 , wherein the nylon material is selected from the group consisting of 4 nylon, 6 nylon, 11 nylon, 12 nylon, 6,10 nylon, 6,12 nylon, 6,14 nylon, 10,10 nylon and 12,12 nylon and other nylon co-polymers.